U.S. patent application number 11/957763 was filed with the patent office on 2008-08-07 for film laminate.
This patent application is currently assigned to Jen-Coat, Inc.. Invention is credited to James Forster, David Hopkins, Terry Leis.
Application Number | 20080188154 11/957763 |
Document ID | / |
Family ID | 39676575 |
Filed Date | 2008-08-07 |
United States Patent
Application |
20080188154 |
Kind Code |
A1 |
Leis; Terry ; et
al. |
August 7, 2008 |
FILM LAMINATE
Abstract
A laminate includes at least one layer of an environmentally
degradable film, for example, a polylactide ("PLA") polymer made
from an annually-renewable, readily-available resource such as
corn. A second layer may be a substrate made from, for example,
paper, woven or non-woven fabrics or metallic foils. The
environmentally degradable film and the substrate are adhered to
one another using, for example, polymeric extrudates or adhesives
such as water-based, hot melt, solvent-based or solvent-less
adhesives. The choice of adherent depends on the type of substrate
to be laminated to the environmentally degradable film and the
desired properties of the resultant composite laminated structure
(i.e., "laminate"). Such film laminates find use, for example, in
the packaging, envelope, tag and label, forms, commercial
publication, and digital print industries. Traditional converting
equipment may be used to convert the film laminate into rolls,
folio sheets and cut size formats as required.
Inventors: |
Leis; Terry; (Huntington,
MA) ; Forster; James; (Haydenville, MA) ;
Hopkins; David; (Southwick, MA) |
Correspondence
Address: |
O'SHEA, GETZ & KOSAKOWSKI, P.C.
1500 MAIN ST., SUITE 912
SPRINGFIELD
MA
01115
US
|
Assignee: |
Jen-Coat, Inc.
Westfield
MA
|
Family ID: |
39676575 |
Appl. No.: |
11/957763 |
Filed: |
December 17, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60888392 |
Feb 6, 2007 |
|
|
|
Current U.S.
Class: |
442/181 ;
428/323; 428/354; 442/394 |
Current CPC
Class: |
Y10T 428/25 20150115;
B32B 7/12 20130101; Y10T 442/674 20150401; Y10T 428/2848 20150115;
Y10T 442/30 20150401 |
Class at
Publication: |
442/181 ;
428/354; 442/394; 428/323 |
International
Class: |
B32B 27/12 20060101
B32B027/12; B32B 7/12 20060101 B32B007/12; B32B 5/16 20060101
B32B005/16 |
Claims
1. A composite laminate structure, comprising: a first layer of a
film that comprises a material that is environmentally degradable
and annually renewable and is independent of a petroleum-based
product; a second layer that comprises a substrate; and an adherent
layer that binds the first layer and the substrate together.
2. The composite laminate structure of claim 1, where the first
layer comprises a polyactide polymer made from vegetable
matter.
3. The composite laminate structure of claim 2, where the vegetable
matter comprises corn.
4. The composite laminate structure of claim 1, where the substrate
comprises a cellulosic product.
5. The composite laminate structure of claim 4, where the
cellulosic product comprises paper or recycled paper.
6. The composite laminate structure of claim 1, where the substrate
comprises woven fabrics, non-woven fabrics, non-metallic films, or
metallic foils.
7. The composite laminate structure of claim 1, where the adherent
layer comprises polymeric extrudates, water-based adhesives, hot
melt, solvent based adhesives or solvent-less adhesives.
8. The composite laminate structure of claim 1, where one or both
surfaces of the first layer are coated with a liquid polymer,
nano-particle dispersions, a metallic deposition or a silicone
oxide deposition such that a gas permeability of the first layer is
reduced.
9. The composite laminate structure of claim 1, where the substrate
comprises paper or recycled paper, and the first layer is treated
by saturation or surface coating with wax or acrylic latex to
impart moisture resistance, reduce gas permeability or improve the
durability of the composite laminate structure.
10. The composite laminate structure of claim 1, further
comprising: a second substrate; and a second adherent layer that
binds the first layer and the second substrate together.
11. A multilayered composite laminate structure, comprising: a
substrate layer having first and second opposing surfaces; a first
layer of a film that comprises a material that is environmentally
degradable and annually renewable and is independent of a
petroleum-based product; a first adherent layer that binds the
first film layer to the first surface of the substrate; a second
layer of a film that comprises a material that is environmentally
degradable and annually renewable and is independent of a
petroleum-based product; and a second adherent layer that binds the
second film layer to the second surface of the substrate.
12. The multilayered composite laminate structure of claim 11,
where the first and second film layers each comprises a polyactide
polymer made from vegetable matter.
13. The multilayered composite laminate structure of claim 12,
where the vegetable matter comprises corn.
14. The multilayered composite laminate structure of claim 11,
where one or both surfaces of each of the first and second film
layers are coated with a liquid polymer, nano-particle dispersions,
a metallic deposition or a silicone oxide deposition such that a
gas permeability of the first and second film layers is
reduced.
15. The multilayered composite laminate structure of claim 11,
where substrate comprises paper or recycled paper, and the first
and second surfaces are treated by saturation or surface coating
with wax or acrylic latex to impart moisture resistance, reduce gas
permeability or improve the durability of the composite laminate
structure.
16. A composite laminate structure, comprising: a first layer of a
film that comprises a material that is environmentally degradable
and annually renewable and is independent of a petroleum-based
product, where the material of the first layer comprises a
polyactide polymer made from vegetable matter; a substrate that
comprises paper or recycled paper, woven fabrics, non-woven
fabrics, non-metallic films, or metallic foils; and an adherent
layer that binds the first layer and the substrate together, where
the adherent layer comprises polymeric extrudates, water-based
adhesives, hot melt, solvent based adhesives or solvent-less
adhesives, where one or both surfaces of the first layer are coated
with a liquid polymer, nano-particle dispersions, a metallic
deposition or a silicone oxide deposition such that a gas
permeability of the first layer is reduced.
17. The composite laminate structure of claim 16, where the
vegetable matter comprises corn.
Description
PRIORITY INFORMATION
[0001] This application claims priority to U.S. Provisional Patent
Application No. 60/888,392 filed Feb. 6, 2007, which is hereby
incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the field of composite
laminated structures or laminates, and in particular to a laminate
having one or more layers each of an environmentally degradable
film and a substrate adhered together.
[0003] Laminates or laminar structures find use in various
industries, including the packaging, envelope, tag and label,
forms, commercial publication, and digital print industries.
Heretofore, no laminate has been able to satisfy the needs of the
markets related to these various industries with regard to an
environmentally-friendly laminate while preserving the desired
attributes in areas such as strength, barrier and
machinability.
[0004] Therefore, there is a need for an improved laminate having
at least one layer of an environmentally degradable film made from
an annually-renewable, readily-available resource such as corn.
SUMMARY OF THE INVENTION
[0005] Briefly, according to the invention, a laminate includes at
least one layer of an environmentally degradable film, preferably
comprising a polylactide ("PLA") polymer made from an
annually-renewable, readily-available resource such as vegetable
matter, for example, corn. A second layer comprises a substrate
such as, for example, paper, woven or non-woven fabrics or metallic
foils. The environmentally degradable film and the substrate are
adhered to one another using, for example, polymeric extrudates or
various types of adhesives such as water-based, hot melt,
solvent-based or solvent-less adhesives. The choice of adherent
depends on type of substrate to be laminated to the environmentally
degradable film and the desired properties of the resultant
composite laminated structure (i.e., "film laminate").
[0006] Film laminates of the present invention find use, for
example, in the packaging, envelope, tag and label, forms,
commercial publication, and digital print industries. Traditional
converting equipment may be used to convert the film laminate of
the present invention into rolls, folio sheets and cut size formats
as required.
[0007] The laminate of the present invention has the advantage that
the film layer included within the laminate is made from an
environmentally degradable, annually-renewable and
readily-available material such as corn. Similar products made not
in accordance with the present invention would typically have a
film layer made from a petroleum-based polymer which is of finite
supply and is not renewable, and which is not readily
environmentally degradable.
[0008] These and other objects, features and advantages of the
present invention will become more apparent in light of the
following detailed description of preferred embodiments thereof, as
illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0009] FIG. 1 is a perspective view of a first embodiment of a
two-layer film laminate and an adhesive binding the layers
according to the invention; and
[0010] FIG. 2 is a perspective view of a second embodiment of a
three-layer film laminate and an adhesive binding the layers
according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Referring to FIG. 1, a first embodiment of a film laminate
10 according to the invention includes a layer 12 of an
environmentally degradable film, preferably a polylactide ("PLA")
polymer derived from vegetable matter (e.g., corn) which by its
nature is an annually-renewable and readily-available resource and
is not derived from or is independent of petroleum. These types of
polymers are environmentally degradable under compost
conditions--that is, these polymers are compostable. Thus,
materials that utilize PLA polymers are inherently environmentally
degradable and use less or no non-renewable resources as compared
to conventional petroleum-based polymers which are much less
environmentally friendly due primarily to the fact that they are
not easily degradable. The film laminate 10 also includes a second
layer 14 of a substrate material. Possible materials for the
substrate 14 may include, for example, a cellulosic product such as
paper including recycled paper. Also, the substrate 14 may
comprise, for example, woven fabrics, non-woven fabrics, various
non-metallic films, or metallic foils. The PLA film layer 12 and
the substrate 14 may be adhered to each other using an adherent
layer 16 that may comprise polymeric extrudates, water-based
adhesives, hot melt, solvent based adhesives or solvent-less
adhesives. The adhesive utilized for the adherent layer 16 depends
upon the one or more substrates 14 to be laminated to the PLA film
layer 12 and the desired properties of the resultant composite
laminated structure 10. A PLA film layer 12 adhered to at least one
substrate 14 enhances the properties of the resultant laminate
10.
[0012] The adherent layer 16 may comprise an environmentally
degradable adhesive such as PLA. Other possible adhesives methods
for forming the film laminate 10 of the present invention may
include polymer extrusion lamination and other conventional
adhesive systems and processes (adhesives such as water-based,
solvent-based, hot-melt, solvent-less, etc). The adherent material
selected can enhance certain properties of the laminate including
but not limited to stiffness, gas permeation barrier, elasticity,
toughness, or moisture resistance.
[0013] If the substrate 14 comprises paper adhered to the PLA film
layer 12 utilizing an environmentally degradable adhesive, the
resultant laminate 10 is fully environmentally degradable under
compost conditions. That is, the film laminate 10 is fully
compostable. Further, if the adherent layer 16 comprises an
adhesive made from renewable resources and the substrate layer 14
comprises paper, the laminate 10 is then fully renewable.
[0014] The PLA film layer 12 or the substrate 14 may be enhanced
through coating of one or both surfaces so that the gas
permeability of the laminate 10 is reduced. The coating may
comprise liquid applications of polymer or nano-particle
dispersions and metallic or silicone oxide deposition. Further, the
substrate 14 formed of paper and/or the PLA film layer 12 may be
treated to impart moisture resistance and to enhance the durability
of the laminate 10. The treatment may be in the form of saturation
or surface coating with, e.g., wax, acrylic latex or similar
substances.
[0015] Referring to FIG. 2, a second embodiment of a film laminate
20 may include a middle layer 22 of, e.g., a PLA film sandwiched
between two outer layers 24, 26 of a substrate material, similar to
the substrate 14 of the embodiment of FIG. 1. The layers may be
adhered together using corresponding layers 28, 30 of an adherent
material similar to the adherent layer 16 of FIG. 1. The resulting
laminate 20 thus has a paper surface on both sides of the laminate
20. Then, if the adherent layers 28, 30 comprise an environmentally
degradable adhesive and the substrate layers 24, 26 comprise paper,
the laminate 20 is fully environmentally degradable under compost
conditions. Further, if the adherent layers 28, 30 comprise an
adhesive made from renewable resources and the substrate layers 24,
26 comprise paper, the laminate 20 is then fully renewable.
[0016] As an alternative to the embodiment of FIG. 2, the middle
layer 22 may comprise the substrate and the outer two layers 24, 26
may comprise the PLA film adhered together in a similar manner to
that described above. The resulting laminate 20 thus has a film
surface on both opposing sides thereof. If the substrate 22
comprises, for example, paper, then the laminate 20 is fully
environmentally degradable under compost conditions. Further, if
the adherent layers 28, 30 comprise an adhesive made from renewable
resources and the substrate layer 22 comprises paper, the laminate
20 is then fully renewable.
[0017] The laminates 10, 20 of FIGS. 1 and 2 can be converted into
rolls, folio sheets and cut size (digital-office-home applications)
format by way of conventional converting machinery. Also, the
laminates 10, 20 may have the outer surfaces of the substrate or
PLA film layer printed with images, data or other information for
various applications.
[0018] In either of the laminates 10, 20 described above and
illustrated herein, different types of cellulose based papers may
be used to provide specific performance, print and converting
requirements for the packaging, envelope, tag and label, forms,
commercial publication, and digital printing industries.
[0019] In the embodiments described above where an outer surface of
the laminate comprises PLA film, and whereas PLA polymer has a low
melt temperature, the laminate can be fused to itself or to another
material using heat and pressure, known as heatsealed. This feature
allows for the formation and closure of packages without the use of
any additional adhesives or sealants. This feature of the invention
allows for the benefits of the laminate to be transferred to the
finished products.
[0020] Although the present invention has been shown and described
with respect to several preferred embodiments thereof, various
changes, omissions and additions to the form and detail thereof,
may be made therein, without departing from the spirit and scope of
the invention.
* * * * *